IGP-DURA®xal is a deep matt decorative powder coating system which is offered in both highly weather-resistant facade quality as series “4201“ (Qualicoat certification class 2), and in weather-resistant industrial quality as series “4601”, all of which are available in plain or pearl mica effect. IGP-DURA®xal effect powder coatings are usually subjected to an additional manufacturing process for optimal application stability using the IGP bonding method, during which the exceptionally fine effect pigments are bonded to the “powder particles”.

It is imperative that all specified process parameters be continuously monitored and observed based on the pre-treatment method. The processing time during the pre-treatment cycle, especially for the rinsing process, may not be shortened. This is the only way to guarantee that the deep matt surface characteristic of the powder coating will not be impaired by impurities in pre-treatment or by an insufficient rinsing process.

Depending on the amount of overspray that is being recycled by the precipitation system, it is possible that when recycling by means of a filter, an increase in effect pigments ratio may occur, and respectively, when recycling by means of a cyclone, a reduction in the effect pigments ratio may occur during the application of IGP-DURA®xal effect coatings.

For powder systems with cyclone recycling, the finest powder and effect particles are not separated in the cyclone, but instead continuously removed from the powder coating. This continuous removal changes the ratio between the basic shade and the effect pigments. This usually causes the shade to appear darker.

In order to prevent shade changes due to loss of effect pigments during the coating process, the application of IGP-DURA®xal effect coatings can be done in normal operation mode without recycling. For automatic coating with the corresponding batch size, assuming that optimal mixing with fresh powder is assured, up to 25% recycled powder can be added. In this case we recommend creating a reference sample prior to the start of production, and to use it to monitor the shade and effect for the entire production. If a deviation of shade and effect occurs, the ratio of fresh powder should be increased accordingly.

We recommend a continuous addition of fresh powder for the application of IGP-DURA®xal without effect pigments.

Due to the deep matt surface and unique surface characteristics of IGP-DURA®xal, even minute differences in the gloss level are very obviously visible. Particular attention should be paid to the curing process because of its significant impact on the gloss level. Fundamentally, an even temperature distribution in the oven is a prerequisite for achieving a uniform deep matt surface throughout all the objects in the suspension gear. The oven temperature is decisive for the intensity of the gloss level. A reduction in the prescribed object temperature leads to an increase in the gloss level. Excessive temperatures cause a reduction in the gloss level.

For optimal cross linking and gloss level consistency with IGP-DURA®xal , we recommend creating a temperature profile of the curing oven with an oven measurement device using production conditions prior to the start of production. This is to determine the optimal time combination of object temperature and retention time, depending on the thickness of the substrate to be coated. Should there be inconsistencies with regard to the temperature distribution in the curing oven, they must be corrected in cooperation with the oven manufacturer by means of ventilation or other additional measures. In any case, taking the recommended curing conditions into consideration, the curing of the coated object should be based on the combination of retention time and object temperature as determined by the oven temperature measurement device.

To achieve the desired deep gloss level, the following temperature and time combinations are recommended:

If the various objects of one order are cured in different ovens, we recommend creating a temperature profile for every curing oven with an oven temperature measurement device and to adjust the curing temperatures of the respective ovens correspondingly.

• The coated parts must be cleaned in accordance with the regulations RAL-GZ 632 or SZFF 61.01
• For effect powder coatings, the IGP TI 106 (Technical Information) must be observed